Method of fabricating an ink droplet generator for an ink jet printer and ink droplet generator fabricated thereby

Abstract

A method is proposed for fabricating components of an ink droplet generator for generating a sequence of charged, detected and deflected ink droplets for an ink jet printer, as is proposed an ink droplet generator fabricated thereby. The method which is based upon multi-layer technology involves forming the charging electrodes and the detection electrodes by removing unnecessary metal coating from a support element metallically coated on at least one side of the support element and forming the deflection electrodes by removing unnecessary metal coating from a polyimide foil coated on at least one side thereof. The polyimide foil is mounted on a substrate constructed as a support element. The arrangement defining the ink droplet generator comprises a first module formed from both board or panel-like support elements and a second module formed from both board or panel-like support elements.

Accordingly, what we claim is: 
     
       1. A method for fabricating components of an ink droplet generator for generating a succession of charged, detected and deflected ink droplets for an ink jet printer, comprising the steps of: removing unrequired electrical conductive coating from metallically coated elements to form a desired configuration of mutually isolated means for charging, detecting and deflecting ink droplets;   configuring a first means of said means as charging electrodes, a second means of said means as detection electrodes and a third means of said means as deflection electrodes;   applying a surface medium resistant to organic and inorganic media at least to a side of each of said first, second and third means which is wetted by an ink droplet medium of the ink jet printer;   said charging electrodes and said detection electrodes being formed upon a first surface of a double-sided coated support element;   
     
     
       a metallic coating of a second surface of said double-sided coated support element being configured and employed as electromagnetic shielding for said charging electrodes and said detection electrodes; said deflection electrodes being formed, conjunctively with therewith associated conductor traces, from a single-sided coated foil and a foil applied thereto; and   said deflection electrodes being applied in sandwich construction to a substrate provided as a support element.   
     
     
       2. The method as defined in claim 1, wherein: said surface medium is a foil.   
     
     
       3. The method as defined in claim 1, wherein: said surface medium is an insulating layer.   
     
     
       4. The method as defined in claim 1, wherein: each said double-sided coated support element provided with said applied foils is fabricated as a hermetically sealed module in multi-layer technology.   
     
     
       5. The method as defined in claim 4, wherein: said applied foil is a polyimide foil.   
     
     
       6. A method for fabricating an ink droplet generator for an ink jet printer in which a succession of ink droplets is charged, monitored and deflected, comprising the steps of: forming and appropriately configuring mutually electrically isolated charging electrode means for imparting an electrostatic charge to the ink droplets, by removing undesired portions of a conductive superstrate of at least one metallically coated board-like support element;   forming and appropriately configuring mutually electrically isolated detection electrode means for monitoring the ink droplets, by removing undesired portions of the conducting superstrate of said at least one metallically-coated board-like support element;   formed and appropriately configuring mutually electrically isolated deflection electrode means for deflecting the ink droplets into a desired trajectory, by removing undesired portions of a conducting superstrate of at least one metallically coated foil:   each of said charging electrode means, said detection electrode means and said deflection electrode means having a side in the ink jet printer which is wetted by the ink droplets;   applying a protective layer resistant to organic and inorganic agents to said wetted sides;   said at least one metallically coated board-like support element comprising electrically conductive superstrates on first and second surfaces of an electrically insulative rigid substrate;   said step of forming said charging electrode means comprising forming a charging electrode upon said first surface of said at least one metallically coated board-like support element;   said step of forming said detection electrode means comprising forming a detection electrode upon said first surface of said at least one metallically coated board-like support element;   a further method step comprising configuring and employing said electrically conductive superstrate of said second surface of said at least one metallically coated board-like support element as electromagnetic shielding means for said charging electrodes and said detection electrodes;   said at least one metallically coated foil comprising an electrically conductive superstrate on a first surface only of at least one electrically insulative foil substrate as well as at least one covering foil applied thereover;   providing at least one support element in the form of a rigid substrate;   said step of forming said deflection electrode means comprising forming at least one deflection electrode conjointly with electrically conductive traces associated therewith upon said first surface of said at least one electrically insulative foil by removing undesired portions of said electrically conductive superstrate; and   a further method step comprising applying said at least one deflection electrode in sandwich construction to said at least one support element in the form of a rigid substrate.   
     
     
       7. The method as defined in claim 6, wherein: said protective layer comprises a foliate material.   
     
     
       8. The method as defined in claim 7, wherein: said protective layer is electrically insulative.   
     
     
       9. The method as defined in claim 6, comprising the further step of: fabricating said at least one metalically coated board-like support element provided with an applied protective foliate material as well as fabricating said at least one support element in the form of a rigid substrate provided with said applied at least one deflection electrode formed upon said first surface of said at least one electrically insulative foil with said at least one covering foil applied thereto as hermetically sealed modules in multi-layer technology.   
     
     
       10. The method as defined in claim 9, wherein: said foliate material, said at least one electrically insulative foil and said at least one covering foil are polyimide foils.   
     
     
       11. An ink droplet generator for generating a sequence of charged, detected and deflected ink droplets, comprising: a first module having a first spacer component and two first panel-like support elements arranged in mutually spaced relationship by said first spacer component;   said two first panel-like support elements being provided with charging and detecting electrodes;   a second module having a second spacer component and two second panel-like support elements arranged in mutually spaced relationship by said second spacer component;   said two second panel-like support elements being provided with deflection electrodes;   a first support element of said two first panel-like support elements comprising a charging electrode of said charging electrodes and a detection electrode of said detection electrodes for a first potential;   a second support element of said two first panel-like support elements comprising a charging electrode of said charging electrodes and a detection electrode of said detection electrodes for a second potential;   said first and second support elements of said two first panel-like support elements and said first spacer component being electrically operatively interconnected by means of plated-through terminals; and   said charging electrodes and said detection electrodes being arranged substantially in mirror-image relationship to one another in an assembled state thereof for forming said first module.   
     
     
       12. The ink droplet generator as defined in claim 11, comprising: a plurality of first modules serially arranged and substantially comprising said first two panel-like support elements;   a plurality of second modules serially arranged and substantially comprising said second two panel-like support elements; and   said second modules being fabricated in sandwich construction and having interior modules and outer modules and with at least said interior modules being arranged between said two outer modules and with at least said interior modules containing a conductor trace for electrical connections on each side thereof.   
     
     
       13. An ink droplet generator for generating a sequence of charged, detected and deflected ink droplets, comprising: a first module having a first spacer component and two first panel-like support elements arranged in mutually spaced relationship by said first spacer component;   said two first panel-like support elements being provided with charging and detecting electrodes;   a second module having a second spacer component and two second panel-like support elements arranged in mutually spaced relationship by said second spacer component;   said two second panel-like support elements being provided with deflection electrodes;   a first support element of said two second panel-like support elements comprising a first deflection electrode of said deflection electrodes for a first potential;   a second support element of said two second panel-like support elements comprising a second deflection electrode of said deflection electrodes for a second potential; and   said first and second deflection electrodes being arranged substantially in mirror-image relationship to one another in an assembled state thereof for forming said second module.   
     
     
       14. The ink droplet generator as defined in claim 13, comprising: a plurality of first modules serially arranged and substantially comprising said first two panel-like support elements;   a plurality of second modules serially arranged and substantially comprising said second two panel-like support elements; and   said second modules being fabricated in sandwich construction and having interior modules and outer modules and with at least said interior modules being arranged between said two outer modules and with at least said interior modules containing a conductor trace for electrical connections on each side thereof.   
     
     
       15. An ink droplet generator of an ink jet printer for generating a succession of charged, monitored and deflected ink droplets, comprising: a first module comprising a first spacer component and first and second rigid support panels arranged in mutually spaced relationship by said first spacer component;   a first charging electrode for imparting an electrostatic charge to the ink droplets and a first detection electrode for detecting the electrostatically charged ink droplets both formed in mutual electrical isolation upon a first side of said first rigid support panel of the first module;   a second charging electrode for imparting an electrostatic charge to the ink droplets and a second detection electrode for detecting the electrostatically charged ink droplets both formed in mutual electrical isolation upon a first side of said second rigid support panel of the first module;   a second module comprising a second spacer component and third and fourth rigid support panels arranged in mutually spaced relationship by said second spacer component;   a first deflection electrode for deflecting the electrostatically charged ink droplets into a desired trajectory and formed upon said third rigid support panel of the second module; and   a second deflection electrode for deflecting the electrostatically charged ink droplets into a desired trajectory and formed upon said fourth rigid support panel of the second panel.   
     
     
       16. The ink droplet generator as defined in claim 15, wherein: a first electrical potential being applied to said first charging electrode;   a second electrical potential being applied to said second charging electrode;   a third electrical potential being applied to said first detection electrode;   a fourth electrical potential being applied to said second detection electrode;   said first and second support panels being assembled together to form said first module such that said first charging electrode and said first detection electrode are arranged in substantially mirror-image relationship to said second charging electrode and said second detection electrode, respectively; and   said first and second rigid support panels and said first spacer component being electrically interconnected by plated-through connection means.   
     
     
       17. The ink droplet generator as defined in claim 16, wherein: said first and third electrical potentials are substantially equal.   
     
     
       18. The ink droplet generator as defined in claim 16, wherein: said second and fourth electrical potentials are substantially equal.   
     
     
       19. The ink droplet generator as defined in claim 16, wherein: a first electrical potential being applied to said first deflection electrode;   a second electrical potential being applied to said second deflection electrode; and   said third and fourth rigid support panels being assembled together to form said second module such that said first deflection electrode is arranged in substantially mirror-image relationship to said second deflection electrode.   
     
     
       20. The ink droplet generator as defined in claim 15, further including: a plurality of said first modules arranged in serial spatial relationship and each substantially comprising said first and second rigid support panels;   a plurality of said second modules arranged in serial spatial relationship and each substantially comprising said third and fourth rigid support panels;   said second modules being fabricated in sandwich construction;   said plurality of second modules comprising two outer second modules and at least one inner second module arranged therebetween; and   at least said at least one inner second module comprising at least one electrically conductive trace on each surface of each said third and fourth rigid support panel for electrical conduction.   
     
     
       21. The ink droplet generator as defined in claim 15, further including: electromagnetic shielding means formed upon a second side of said first rigid support panel; and   electromagnetic shielding means formed upon a second side of said second rigid support panel.